As one of the most typical components in the manufacturing industry, integral impellers are widely used in aviation, aerospace, modern turbomachinery, compressors, turbine machinery, rocket propulsion systems, and other fields. With technological advancements in products, impellers made from titanium alloys, superalloys, and heat-resistant stainless steel have evolved from initial radial straight blades to complex spatial curved blades with backward sweep and forward lean. Moreover, impeller blades are long, thin, and exhibit poor rigidity. From a machining perspective, both the material properties and structural complexity of the component impose higher demands on mechanical processing. To achieve precise machining of these intricate impeller shapes, four-axis or five-axis multi-axis CNC machine tools are now widely adopted for impeller manufacturing.
Rough Processing
Rough machining of titanium alloys, superalloys, and die steels is performed using the specially developed SKG high-feed milling cutters. Featuring low-resistance S-shaped inserts with a small lead angle, the SKG cutter directs over 90% of the cutting force axially. Its peripheral relief geometry is optimized for impeller thin-wall structures and complex profiling, significantly boosting roughing efficiency while reducing tooling costs. The latest coating technology delivers a breakthrough improvement in tool durability during machining of difficult-to-cut materials like titanium alloys and superalloys, enabling continuous machining for over 150 minutes per insert indexing.
Application Case:
Integral impeller, material: titanium alloy TC4, hardness HB 280-320
Tool Specifications:
Tool Model: SKG-5040R-09-16
Insert Model: SDET090312ZDER-SM
Cutting Speed Vc (m/min): 56.52
Spindle Speed n (rev/min): 450
Feed per Tooth Fz (mm/t): 0.53
Feed Rate Vf (mm/min): 1200
Depth of Cut ap (mm): 0.7
Radial Depth of Cut ae (mm): 32
Finishing
Precision machining is performed using STLP cutters. As a specialized 5-axis milling tool series, the STLP features a barrel-taper ball-nose end mill structure. When machining workpieces on 5-axis equipment, it fully utilizes the large-R arc tapered side cutting edges. Compared to ball-nose cutters of identical diameter:
Achieves 6-8 times larger stepover while maintaining identical surface finish
Barrel cutting edges generate significantly lower cutting forces
Enhanced contour-following capability
Superior vibration resistance
thereby dramatically reducing cycle time and maximizing utilization of expensive five-axis machines.
Application Case:
Integral impeller, material: titanium alloy TC4, hardness 40 HRC
Tool Specifications for Precision Machining:
Tool Model: STLP4200T15R4-M10
Cutting Speed Vc (m/min): 201
Spindle Speed n (rev/min): 3,200
Feed per Tooth Fz (mm/t): 0.14
Feed Rate Vf (mm/min): 1,800
Depth of Cut ap (mm): 2.5
Radial Depth of Cut ae (mm): 0.4
Based on the impeller machining case studies presented, we encourage you to leverage Joy Cutting Tools® high-efficiency, high-precision cutting tools to:
• Enhance production efficiency
• Elevate product quality
• Strengthen market competitiveness
Joy Cutting Tools remains committed to staying attuned to every customer's needs, continuously developing and delivering innovative products and machining technologies to ensure your utmost satisfaction!
